Apparatus for and methods of attaching heat slugs to package tops

ABSTRACT

A frame includes heat slug pads coupled together in a N×M matrix such that singulation of the heat slug pads consists of one or more passes across the frame, wherein the one or more passes are parallel. A method of attaching heat slug pads to packages includes gathering a plurality of packages, preparing a heat slug frame including a N×M matrix of heat slug pads, dispensing thermally conductive material onto surfaces of the heat slug pads, attaching the plurality of packages onto the heat slug pads, and singulating the heat slug pads, wherein the singulating step consists of one or more parallel passes across the N×M matrix. A method of attaching heat slug foil to packages includes preparing a plurality of packages, laminating the heat slug foil to one side of the plurality of packages using thermally conductive material, and singulating the plurality of packages.

RELATED APPLICATIONS

This application claims benefit of priority under 35 U.S.C. section 119(e) of the co-pending U.S. Provisional Patent Application Ser. No. 61/320,652, filed Apr. 2, 2010, entitled “PACKAGE WITH Heat slug pad,” which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention is related to the field of semiconductor device manufacturing. More specifically, the present invention relates to an apparatus for and methods of attaching heat slugs to package tops.

BACKGROUND

A heat slug leadframe provides mechanical support to semiconductor packages during assembly into finished products. FIG. 1A illustrates a prior art heat slug leadframe 100. The heat slug leadframe 100 has a N×M matrix of heat slug pads 105 coupled together or to the frame 120 using tie bars 110 a, 110 b. As illustrated, the tie bars 110 a, 110 b couple vertically and horizontally adjacent heat slug pads 105 together. In particular, each heat slug pad uses tie bars 110 a, 110 b on all sides of the heat slug pad to couple to other heat slug pads 105 and/or to the frame 120. Vertical and horizontal cuts 115 a, 115 b across the matrix during singulation are thus needed to separate the heat slug pads 105 from each other and the frame. Due to the time required to take the multiple passes (i.e., vertical passes and horizontal passes) across the matrix for singulation, the prior art leadframe 100 therefore has a low units per hour (UPH) output value. Further, the required passes across the matrix not only causes high blade wear, but singulating the heat slug pads 105 with packages (not illustrated) coupled thereto has a high potential of cracking or chipping these packages. These cracked or chipped packages are unusable. Such damages can become costly.

FIG. 1B illustrates a cross section view along the line A-A of the prior heat slug leadframe of FIG. 1A. There are two types of tie bars. The first type of tie bar 110 b 1 is not etched and has the same thickness as a heat slug pad 105. The second type of tie bar 110 b 2 is etched and has, for example, half the thickness as a heat slug pad 105 to help reduce or minimize blade wear. However, a heat slug leadframe having the second type of tie bar 110 b 2 has the same disadvantage as a heat slug leadframe having the first type of tie bar 110 b 1 in that it has a low UPH and a high potential of damaging the packages coupled thereto due to the required multiple passes across the matrix of heat slug pads for singulation. What is needed is a leadframe that requires less passes across the leadframe during singulation to reduce or minimize blade wear and/or the potential of cracking or chipping packages thereon.

SUMMARY OF THE DISCLOSURE

The term “heat slug” refers to either a heat slug pad or heat slug foil. However, it should be apparent from the disclosure how the term “heat slug” is used.

In one aspect, a frame includes heat slug pads that are coupled together in a N×M matrix such that singulation of the heat slug pads consists of one or more parallel passes across the frame. The thickness of each heat slug pad is typically between 0.02 mm and 1.0 mm. Each heat slug pad is coupled to another heat slug pad using one or more tie bars. In some embodiments, each heat slug pad has one or more tie bars on each non-adjacent side of the heat slug pad. The one or more tie bars in some embodiments do not have the same thickness as the heat slug pads. In some embodiments, the thickness of a tie bar is smaller than the thickness of a heat slug pad. In some embodiments, the tie bars are etched or stamped. In some embodiments, each heat slug pad includes one or more fiducial alignment marks to aid placement of a package onto the heat slug pad. The heat slug pad can be etched or stamped to obtain a desired form. In some embodiments, at least a portion of the heat slug pad is half the total thickness of the heat slug pad. In some embodiments, the heat slug pad includes a protrusion along a portion of the heat slug pad. The protrusion extends between 0.1 mm and 0.2 mm from an edge of the package coupled to the heat slug. The protrusion advantageously minimizes blade wear and prevents chips and/or cracks to the package because the protrusion provides for enough spacing between the package and the singulation device. In some embodiments, the heat slug pad includes at least two walls to position the package therebetween when the package is coupled to the heat slug. In some embodiments, the heat slug pads comprise copper or a metal alloy.

In another aspect, a method is directed to attaching heat slug pads to packages. A plurality of packages is gathered. The packages are typically singulated. In some embodiments, the packages are wafer level chip scale packages, flip-chip quad flat non-lead packages or wire-bond quad flat non-lead packages. Other packages are contemplated.

A heat slug frame is then prepared. Typically, the heat slug frame includes a N×M matrix of heat slug pads coupled together. In some embodiments, the heat slug pads are formed by etching or stamping such that a protrusion is created along a portion of each heat slug pad. The protrusion typically extends between 0.1 mm and 0.2 mm from an edge of a package coupled to the heat slug. In some embodiments, the heat slug pads formed such that each heat slug pad includes at least two walls to position the package therebetween. At least a portion of the heat slug pad is half the total thickness of the heat slug pad. In some embodiments, the heat slug pads are marked with fiducial alignment marks to aid placement of the package onto the heat slug pad. The etching or stamping of the heat slug pads advantageously minimizes blade wear and prevents chips and/or cracks to packages. Each heat slug pad is typically coupled to another heat slug pad using one or more tie bars. In some embodiments, each heat slug pad has one or more tie bars on each non-adjacent side of the heat slug pad. The one or more tie bars in some embodiments are etched. Alternatively, the one or more tie bars are stamped.

Thermally conductive material is then dispensed onto surfaces of the heat slug pads. The plurality of packages is attached onto the heat slug pads. If fiducial alignment marks exist on the heat slug pads, then the marks are used to align the plurality of packages to the heat slug pads according to fiducial alignment marks on the heat slug pads. After placing the packages on the heat slug pads, the thermally conductive material is cured. The heat slug pads (with the packages thereon) are singulated. Typically, singulation consists of one or more passes across the N×M matrix, wherein the one or more passes are parallel.

Yet in another aspect, a method is directed to attaching heat slug foil to packages. A plurality of packages is prepared. Typically, the prepared packages are not singulated. In some embodiments, the packages are wafer level chip scale packages, flip-chip quad flat non-lead packages or wire-bond quad flat non-lead packages. Other packages are contemplated. Heat slug foil is then laminated to one side of the packages using thermally conductive material. The thermally conductive material is cured. After the thermally conductive material is cured, the plurality of packages is singulated.

Yet in another aspect, a method is directed to forming a heat slug leadframe. A heat slug leadframe is first obtained. Typically, the heat slug leadframe includes at least one heat slug pad and one or more tie bars on each non-adjacent side of the at least one heat slug pad. The heat slug pad is prepared such that the heat slug pad has varying thickness across the heat slug pad. The heat slug pad is further formed to obtain a desired design. The heat slug pad is formed by etching. Alternatively, the heat slug pad is formed by stamping. In some embodiments, the prepared heat slug pad includes a protrusion along a portion of the heat slug pad. Alternatively or in addition to, the prepared heat slug pad includes at least two walls configured to position a package therebetween when the package is coupled to the heat slug pad. In some embodiments, the heat slug pad is further marked with one or more fiducial alignment marks. In some embodiments, the one or more tie bars are formed. The one or more tie bars are formed by etching. Alternatively, the one or more tie bars are formed by stamping.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the invention are set forth in the appended claims. However, for purpose of explanation, several embodiments of the invention are set forth in the following figures.

FIG. 1A illustrates a prior art heat slug leadframe.

FIG. 1B illustrates a cross section view of the line A-A in FIG. 1B.

FIGS. 2A-2B illustrate two embodiments of a heat slug leadframe in accordance with the present invention.

FIG. 2C illustrates various embodiments of tie bar designs in accordance with the present invention.

FIG. 2D illustrates various embodiments of physical fiducial alignment mark designs in accordance with the present invention.

FIG. 3A illustrates a method of attaching heat slug pads to packages in accordance with the present invention.

FIG. 3B illustrates a graphical process of producing WLCSPs (wafer level chip scale packages) with attached heat slug pads in accordance with the present invention.

FIG. 3C illustrates a graphical process of producing FC-QFN (flip-chip quad flat non-lead) packages with attached heat slug pads in accordance with the present invention.

FIG. 3D illustrates a graphical process of producing WB-QFN (wire-bond quad flat non-lead) packages with attached heat slug pads in accordance with the present invention.

FIGS. 4A-4N illustrate different embodiments of the heat slug pads in accordance with the present invention.

FIG. 5A illustrates a method of attaching heat slug foil to packages in accordance with the present invention.

FIG. 5B illustrates a graphical process of producing WLCSPs (wafer level chip scale packages) with attached heat slug pads in accordance with the present invention.

FIG. 5C illustrates a graphical process of producing FC-QFN (flip-chip quad flat non-lead) packages with attached heat slug pads in accordance with the present invention.

FIG. 5D illustrates a graphical process of producing WB-QFN (wire-bond quad flat non-lead) packages with attached heat slug pads in accordance with the present invention.

FIGS. 6A-6H illustrate representative packages in accordance with the present invention.

DETAILED DESCRIPTION

In the following description, numerous details are set forth for purposes of explanation. However, one of ordinary skill in the art will realize that the invention can be practiced without the use of these specific details. Thus, the present invention is not intended to be limited to the embodiments shown but is to be accorded the widest scope consistent with the principles and features described herein or with equivalent alternatives.

Reference will now be made in detail to implementations of the present invention as illustrated in the accompanying drawings. The same reference indicators will be used throughout the drawings and the following detailed description to refer to the same or like parts.

Embodiments of the present invention are directed to an apparatus for and methods of attaching heat slugs to package tops. The term “heat slug” refers to either a heat slug pad or heat slug foil, each of which is described below. It should be apparent from the disclosure how the term “heat slug” is used.

Heat Slug Pads

In some embodiments, the apparatus is a frame comprising heat slug pads coupled together in a N×M matrix such that singulation of the heat slug pads consists of one or more passes across the frame, wherein the one or more passes are parallel. As is evidenced herein, the frame according to the present invention advantageously saves material costs and production time, and reduces the potential of damaging the heat slug pads and/or packages thereon during singulation.

FIG. 2A illustrates one embodiment of a heat slug leadframe 200 in accordance with the present invention. The heat slug leadframe 200 typically comprises a N×M matrix of heat slug pads 205. As illustrated, the heat slug pads 205 in the m^(th) position or column of each row in the matrix are coupled together using tie bars 210. Unlike the prior art heat slug pads 105 of FIG. 1A, each heat slug pad 205 of the present invention has tie bars only on non-adjacent sides of the heat slug pad 205 to couple to other heat slug pads and/or to the frame 220 such that only one or more parallel passes 215 are needed during singulation to separate the heat slug pads 205. Put differently, the heat slug pads 205 are coupled to other heat slug pads 205 in adjacent row or adjacent columns, but not both. Since the number of passes during singulation is greatly reduced (as compared to that in the prior art), blade wear is significantly reduced.

In some embodiments, the tie bars 210 are etched to further minimize blade wear and/or reduce package chips/cracks during singulation. Alternatively, the tie bars 210 are stamped to minimize blade wear and/or reduce package chips/cracks during singulation. Similar to that illustrated in FIG. 1B, the tie bars 210 do not have the same thickness as the heat slug pads 205.

In some embodiments, each heat slug pad 205 is also etched to obtain a desired from of the heat slug pads 205. As illustrated in FIGS. 2A and 2C-2D (bottom rows), the circumference of each heat slug pad 205 is etched. Alternatively, only the sides of where the tie bars are coupled to on the heat slug pads 205 are etched (FIGS. 2C and 2D, second rows). Alternatively, the centers of the heat slug pads 205 etched (FIGS. 4F and 4N). Alternatively, both top and bottom of the heat slug pad 205 are etched to create, for example, a middle protrusion (FIGS. 4E and 4I-4J). In other embodiments, heat slug pads 205 can be stamped to obtain the desired form of the heat slug pads 205. Both the etching process and the stamping process not only “cut” but also “form” different thicknesses of the heat slug leadframe 200.

FIG. 2B illustrates another embodiment of a heat slug leadframe 200′ in accordance with the present invention. The heat slug leadframe 200′ is similarly configured as the heat slug leadframe 200; however, the heat slug pads 205′ are not etched or stamped. These non-formed heat slug pads are also shown in FIGS. 2C-2D (top rows).

In some embodiments, the thickness of the heat slug pads is approximately between 0.02 mm and 1.0 mm, although other thicknesses are contemplated. Typically, the heat slug pads are made from copper, although other metal alloys are contemplated.

Although a single tie per side is illustrated in FIGS. 2A-2B, multiple tie bars per side can be used, for example, with larger heat slug pads. FIG. 2C illustrates various embodiments of tie bar designs in accordance with the present invention. All embodiments of the heat slug pads include tie bars on only non-adjacent sides of each heat slug pad so as to reduce the number of passes across the heat slug lead frame during singulation. In particular, a heat slug pad has one or more tie bars on each of the two, opposite sides of the heat slug pad so as to couple to other heat slug pads either vertically or horizontally, but not both. In some embodiment, only one pair of tie bars is coupled to the non-adjacent sides. (A “pair” is defined as two tie bars; one tie bar on one side, and the other tie bar on the opposite side.) In other embodiments, multiple pairs of tie bars are coupled to the non-adjacent sides. Multiple pairs of tie bars can be used with larger heat slug pads to securely couple the larger heat slug pads to the frame 220. Although FIG. 2C illustrates three patterns of the heat slug pads (first row heat slug pads are not formed by etching or stamping; second row heat slug pads formed by etching or stamping such that portions along two non-adjacent sides of the heat slug pads are removed; third or last row heat slug pads are formed by etching or stamping such that portions around the circumferences of the heat slug pads are removed), other patterns of the heat slug pads are contemplated.

In some embodiments, heat slug pads have optical or physical fiducial alignment marks on the surfaces of the heat slug pads. Fiducial alignment marks provide reference points for high precision alignment of attaching packages to the heat slug pads. Fiducial alignment marks advantageously decrease the time needed to locate accurate placement of the packages.

FIG. 2D illustrates various embodiments of physical fiducial alignment mark designs in accordance with the present invention. As illustrated, some embodiments have a cross marking at the center, while other embodiments have both a cross marking and corner markings. While only two mark designs are shown, other mark designs are contemplated. Typically, fiducial alignment markings vary depending on the shape of the package and/or the attachment equipment capability.

The heat slug leadframes 200, 200′ of the present invention advantageously reduce the number of passes required to separate the heat slug pads 205, 205′ from each other and/or the frame 220. As such, the heat slug leadframes 200, 200′ have a higher units per hour (UPH) output value than that of prior art leadframe 100. The reduced number of passes across the matrix during singulation minimizes blade wear and/or reduces the potential of cracking or chipping the packages coupled thereon.

FIG. 3A illustrates an embodiment of a method 300 of attaching heat slug pads to packages in accordance with the present invention. The method 300 begins at a step 305, wherein a plurality of packages is gathered. In some embodiments, the gathering step includes singulating the plurality of packages from a wafer, a strip or the like. At a step 310, a heat slug frame comprising a N×M matrix of heat slug pads is prepared (as in FIGS. 2A-2B). In some embodiments, the preparing step includes etching or stamping the heat slug pads, the tie bars, or both. At a step 315, thermally conductive material is dispensed onto the surfaces of the heat slug pads. At a step 320, the plurality of packages is coupled to the heat slug pads with the thermally conductive material therebetween. At a step 325, the heat slug pads having the plurality of packages thereon are singulated via, for example, saw singulation, laser singulation or punch singulation. Typically, the singulating step consists of one or more passes across the N×M matrix, wherein the one or more passes are parallel. The method 300 thereafter ends.

FIG. 3B illustrates an embodiment of a graphical process of producing WLCSPs (wafer level chip scale packages) with attached heat slug pads in accordance with the present invention. At a step 1, singulated WLCSPs from a wafer are gathered. At a step 2, a heat slug frame is prepared. The heat slug frame can be optionally etched or stamped depending on application. As illustrated, the both the heat slug pads and the tie bars are etched or stamped. However, in other embodiments, neither the tie bars, the heat slug pads, nor both are etched or stamped. Heat slug pads are typically coupled to other heat slug pads using tie bars. Preferably, heat slug pads include one or more pairs of tie bars on only non-adjacent sides of the heat slug pads such that singulation of the heat slug pads requires only one or more parallel passes. At a step 3, thermally conductive material is dispensed onto the heat slug pads. At a step 4, the WLCSPs are picked up and are coupled to the heat slug pads at a step 5. In particular, the heat slug pads are coupled to the passive side of the WLCSPs. At a step 6, the thermally conductive material is cured. At a step 7, the heat slug pads with the packages coupled thereto are singulated using parallel passes, resulting in WLCSPs with attached heat slug pads. As illustrated, a finished product has a heat slug pad coupled to the package. The width of the interfacing planar surface of the heat slug pad is greater than the width of the exposed planer surface of the heat slug pad and the width of the attached package. This extended interfacing planar surface advantageously reduces the potential of damaging the heat slug pad and of cracking or chipping the package during singulation because the protrusion provides for enough spacing between the package and the singulation device to avoid damage to the package.

FIG. 3C illustrates an embodiment of a graphical process of producing FC-QFN (flip-chip quad flat non-lead) packages with attached heat slug pads in accordance with the present invention. At a step 1, a FC-QFN packages from a molded strip are gathered. At a step 2, a heat slug frame is prepared. The heat slug frame can be optionally etched or stamped depending on application. As illustrated, the both the heat slug pads and the tie bars are etched or stamped. However, in other embodiments, neither the tie bars, the heat slug pads, nor both are etched or stamped. Heat slug pads are typically coupled to other heat slug pads using tie bars. Preferably, heat slug pads include one or more pairs of tie bars on only non-adjacent sides of the heat slug pads such that singulation of the heat slug pads requires only one or more parallel passes. At a step 3, thermally conductive material is dispensed onto the heat slug pads. At a step 4, the FC-QFN packages are picked up and are coupled to the heat slug pads at a step 5. In particular, the heat slug pads are coupled to the passive side of the FC-QFN packages. At a step 6, the thermally conductive material is cured. At a step 7, the heat slug pads with the packages coupled thereto are singulated using parallel passes, resulting in FC-QFN packages with attached heat slug pads. As illustrated, a finished product has a heat slug pad coupled to the package. The width of the interfacing planar surface of the heat slug pad is greater than the width of the exposed planer surface of the heat slug pad and the width of the attached package. This extended interfacing planar surface advantageously reduces the potential of damaging the heat slug pad and of cracking or chipping the package during singulation because the protrusion provides for enough spacing between the package and the singulation device to avoid damage to the package.

FIG. 3D illustrates an embodiment of a graphical process of producing WB-QFN (wire-bond quad flat non-lead) packages with attached heat slug pads in accordance with the present invention. At a step 1, a WB-QFN packages from a molded strip are gathered. At a step 2, a heat slug frame is prepared. The heat slug frame can be optionally etched or stamped depending on application. As illustrated, the both the heat slug pads and the tie bars are etched or stamped. However, in other embodiments, neither the tie bars, the heat slug pads, nor both are etched or stamped. Heat slug pads are typically coupled to other heat slug pads using tie bars. Preferably, heat slug pads include one or more pairs of tie bars on only non-adjacent sides of the heat slug pads such that singulation of the heat slug pads requires only one or more parallel passes. At a step 3, thermally conductive material is dispensed onto the heat slug pads. At a step 4, the WB-QFN packages are picked up and are coupled to the heat slug pads at a step 5. In particular, the heat slug pads are coupled to the active side of the WB-QFN packages. At a step 6, the thermally conductive material is cured. At a step 7, the heat slug pads with the packages coupled thereto are singulated using parallel passes, resulting in WB-QFN packages with attached heat slug pads. As illustrated, a finished product has a heat slug pad coupled to the package. The width of the interfacing planar surface of the heat slug pad is greater than the width of the exposed planer surface of the heat slug pad and the width of the attached package. This extended interfacing planar surface advantageously reduces the potential of damaging the heat slug pad and of cracking or chipping of the package during singulation because the protrusion provides for enough spacing between the package and the singulation device to avoid damage to the package.

Although the processes of producing WLCSPs, FC-QFN packages and WB-QFN packages with attached heat slug pads are discussed in FIGS. 3B-3D, other types of packages can be coupled to the heat slug pads according to method 300. Other exemplary types of packages are discussed below.

FIGS. 4A-4N illustrate different embodiments of the heat slug pads 415 in accordance with the present invention. As discussed above, the heat slug pads 415 can be etched or stamped to obtain a desired form. In these figures, the heat slug pads 415 are coupled to packages 405 using thermally conductive material 410. For the sake of clarity, the packages 405 are shown as blocks. The packages 405 can be any type of packages, including the previously discussed WLCSPs, FC-QFN packages and WB-QFN packages.

FIG. 4A illustrates a heat slug pad 415 a coupled to a package 405 a using thermally conductive material 410 a. The heat slug pad 415 a has an exposed planar surface 420 a and an interfacing planar surface 425 a. The interfacing planar surface 425 a interfaces with the package 405 a. The exposed planar surface 420 a and the interfacing planar surface 425 a of the heat slug pad 415 a have the same width as the package 405 a. It is intended that other thicknesses can be configured.

FIG. 4B illustrates a heat slug pad 415 b coupled to a package 405 b using thermally conductive material 410 b. The heat slug pad 415 b has an exposed planar surface 420 b and an interfacing planar surface 425 b. The interfacing planar surface 425 b interfaces with the package 405 b. The exposed planar surface 420 b and the interfacing planar surface 425 b of the heat slug pad 415 b has a smaller width than the package 405 b. It is intended that other thicknesses can be configured.

FIG. 4C illustrates a heat slug pad 415 c coupled to a package 405 c using thermally conductive material 410 c. The heat slug pad 415 c has an exposed planar surface 420 c and an interfacing planar surface 425 c. The interfacing planar surface 425 c interfaces with the package 405 c. The heat slug pad 415 c has a second planar surface 430 c. The exposed planar surface 420 c has a smaller width than the interfacing planar surface 425 c. The interfacing planar surface 425 c has the same width as or a smaller width than the package 405 c. In some embodiments, the thickness from the second planar surface 430 c to the interfacing planar surface 425 c is half the thickness from the exposed planar surface 420 c to the interfacing planar surface 425 c. It is intended that other thicknesses can be configured.

FIG. 4D illustrates a heat slug pad 415 d coupled to a package 405 d using thermally conductive material 410 d. The heat slug pad 415 d is a flipped embodiment of heat slug pad 415 c. In particular, the heat slug pad 415 d has an exposed planar surface 420 d and an interfacing planar surface 425 d. The interfacing planar surface 425 d interfaces with the package 405 d. The heat slug pad 415 d has a second planar surface 430 d, which is below the exposed planar surface 420 d. The interfacing planar surface 425 d has a smaller width than the package 405 d. The exposed planar surface 420 d has the same width as or a smaller width than the package 405 d but larger than the interfacing planar surface 425 d. In some embodiments, the thickness from the exposed planar surface 420 d to the second planar surface 430 d is half the thickness from the exposed planar surface 420 d to the interfacing planar surface 425 d. It is intended that other thicknesses can be configured.

FIG. 4E illustrates a heat slug pad 415 e coupled to a package 405 e using thermally conductive material 410 e. The heat slug pad 415 e has an exposed planar surface 420 e and an interfacing planar surface 425 e. The interfacing planar surface 425 e interfaces with the package 405 e. The exposed planar surface 420 e has the same width as the interfacing planar surface 425 e, both of which have a smaller width than the package 405 e. The heat slug pad 415 e has a middle section between a second planar surface 430 e and a third planar surface 435 e. The middle section has a same width as or a smaller width than the package 405 e. In some embodiments, the thickness of the middle section is half the thickness from the exposed planar surface 420 e to the interfacing planar surface 425 e. It is intended that other thicknesses can be configured.

FIG. 4F illustrates a heat slug pad 415 f coupled to a package 405 f using thermally conductive material 410 f. The heat slug pad 415 f has a top planar surface 420 f, an interfacing planar surface 430 f, and a bottom planar surface 425 f. The interfacing planar surface 430 f interfaces with the package 405 f. A center portion of the heat slug pad 415 f is removed to create the interfacing planar surface 430 f and walls to surround a portion of the package 405 f. In some embodiments, the thickness from the top planar surface 420 f to the interfacing planar surface 430 f is half the thickness from the top planar surface 420 f to the bottom planar surface 425 f. It is intended that other thicknesses can be configured.

FIG. 4G illustrates a heat slug pad 415 g coupled to a package 405 g using thermally conductive material 410 g. The heat slug pad 415 g is similarly configured as the heat slug pad 415 c, except that a portion of the heat slug pad 415 g extends beyond the edge of the package 405 g. In particular, the heat slug pad 415 g has an exposed planar surface 420 g and an interfacing planar surface 425 g. The interfacing planar surface 425 g interfaces with the package 405 g. The heat slug pad 415 g has a second planar surface 430 g. The exposed planar surface 420 g has a smaller width than the package 405 g. The interfacing planar surface 425 g has a larger width than the package 405 g. In some embodiments, the interfacing planar surface 425 g protrudes approximately 0.1 mm to 0.2 mm from the edges of the package 405 g. In some embodiments, the thickness from the second planar surface 430 g to the interfacing planar surface 425 g is half the thickness from the exposed planar surface 420 g to the interfacing planar surface 425 g. It is intended that other thicknesses can be configured.

FIG. 4H illustrates a heat slug pad 415 h coupled to a package 405 h using thermally conductive material 410 h. The heat slug pad 415 h is similarly configured as the heat slug pad 415 g, except that an exposed planar surface 420 h has a larger width than the exposed planar surface 420 g. In particular, the heat slug pad 415 h has the exposed planar surface 420 h and an interfacing planar surface 425 h. The interfacing planar surface 425 h interfaces with the package 405 h. The heat slug pad 415 h has a second planar surface 430 h. The exposed planar surface 420 h has the same width as the package 405 h. The interfacing planar surface 425 h has a larger width than the package 405 h. In some embodiments, the interfacing planar surface 425 h protrudes approximately 0.1 mm to 0.2 mm from the edges of the package 405 h. In some embodiments, the thickness from the second planar surface 430 h to the interfacing planar surface 425 h is half the thickness from the exposed planar surface 420 h to the interfacing planar surface 425 h. It is intended that other thicknesses can be configured.

FIG. 4I illustrates a heat slug pad 415 i coupled to a package 405 i using thermally conductive material 410 i. The heat slug pad 415 i is similarly configured as the heat slug pad 415 d, except that a portion of the heat slug pad 415 i extends beyond the edge of the package 405 i. In particular, the heat slug pad 415 i has an exposed planar surface 420 i and an interfacing planar surface 425 i. The interfacing planar surface 425 i interfaces with the package 405 i. The heat slug pad 415 i has a second planar surface 430 i, which is below the exposed planar surface 420 i. The interfacing planar surface 425 i has a smaller width than the package 405 i. The exposed planar surface 420 i has a larger width than the package 405 i. In some embodiments, the exposed planar surface 420 i protrudes approximately 0.1 mm to 0.2 mm from the edges of the package 405 i. In some embodiments, the thickness from the exposed planar surface 420 i to the second planar surface 430 i is half the thickness from the exposed planar surface 420 i to the interfacing planar surface 425 i. The heat slug pad 415 i is a flipped embodiment of heat slug pad 415 g. It is intended that other thicknesses can be configured.

FIG. 4J illustrates a heat slug pad 415 j coupled to a package 405 j using thermally conductive material 410 j. The heat slug pad 415 j is similarly configured as the heat slug pad 415 i, except that an interfacing planar surface 425 j has a larger width than the interfacing planar surface 425 i. In particular, the heat slug pad 415 j has an exposed planar surface 420 j and the interfacing planar surface 425 j. The interfacing planar surface 425 j interfaces with the package 405 j. The heat slug pad 415 j has a second planar surface 430 j, which is below the exposed planar surface 420 j. The interfacing planar surface 425 j has the same width than the package 405 j. The exposed planar surface 420 j has a larger width than the package 405 j. In some embodiments, the exposed planar surface 420 j protrudes approximately 0.1 mm to 0.2 mm from the edges of the package 405 j. In some embodiments, the thickness from the exposed planar surface 420 j to the second planar surface 430 j is half the thickness from the exposed planar surface 420 j to the interfacing planar surface 425 j. The heat slug pad 415 j is a flipped embodiment of heat slug pad 415 h. It is intended that other thicknesses can be configured.

FIG. 4K illustrates a heat slug pad 415 k coupled to a package 405 k using thermally conductive material 410 k. The heat slug pad 415 k is similarly configured as the heat slug pad 415 e, except that a portion of the heat slug pad 415 k extends beyond the edge of the package 405 k. In particular, heat slug pad 415 k has an exposed planar surface 420 k and an interfacing planar surface 425 k. The interfacing planar surface 425 k interfaces with the package 405 k. The exposed planar surface 420 k has the same width as the interfacing planar surface 425 k, both of which have a smaller width than the package 405 k. The heat slug pad 415 k has a middle section between a second planar surface 430 k and a third planar surface 435 k. The middle section has a larger width than the package 405 k. In some embodiments, the middle section protrudes approximately 0.1 mm to 0.2 mm from the edges of the package 405 k. In some embodiments, the thickness of the middle section is half the thickness from the exposed planar surface 420 k to the interfacing planar surface 425 k. It is intended that other thicknesses can be configured.

FIG. 4L illustrates a heat slug pad 415 l coupled to a package 405 l using thermally conductive material 410 l. The heat slug pad 415 l is similarly configured as the heat slug pad 415 k, except that an exposed planar surface 420 l and an interfacing planar surface 425 l have a larger width than the exposed planar surface 420 k and the interfacing planar surface 425 k, respectively. In particular, heat slug pad 415 l has the exposed planar surface 420 l and the interfacing planar surface 425 l. The interfacing planar surface 425 l interfaces with the package 405 l. The exposed planar surface 420 l has the same width as the interfacing planar surface 425 l, both of which have the same width than the package 405 l. The heat slug pad 415 l has a middle section between a second planar surface 430 l and a third planar surface 435 l. The middle section has a larger width than the package 405 l. In some embodiments, the middle section protrudes approximately 0.1 mm to 0.2 mm from the edges of the package 405 l. In some embodiments, the thickness of the middle section is half the thickness from the exposed planar surface 420 l to the interfacing planar surface 425 l. It is intended that other thicknesses can be configured.

FIG. 4M illustrates a heat slug pad 415 m coupled to a package 405 m using thermally conductive material 410 m. The heat slug pad 415 m has an exposed planar surface 420 m and an interfacing planar surface 425 m. The interfacing planar surface 425 m interfaces with the package 405 m. The heat slug pad 415 m has a larger width than the package 405 m. In some embodiments, the heat slug 415 m protrudes approximately 0.1 mm to 0.2 mm from the edges of the package 405 m. It is intended that other thicknesses can be configured.

FIG. 4N illustrates a heat slug pad 415 n coupled to a package 405 n using thermally conductive material 410 n. The heat slug pad 415 n is similarly configured as the heat slug pad 415 f, except that a portion of the heat slug pad 415 n extends beyond the edge of the package 405 n. In particular, the heat slug pad 415 n has a top planar surface 420 n, an interfacing planar surface 430 n, and a bottom planar surface 425 n. The interfacing planar surface 430 n interfaces with the package 405 n. A center portion of the heat slug pad 415 n is removed to create the interfacing planar surface 430 n and walls to surround a portion of the package 405 n. In some embodiments, the thickness from the top planar surface 420 n to the interfacing planar surface 430 n is half the thickness from the top planar surface 420 n to the bottom planar surface 425 n. In some embodiments, the top planar surface 420 n protrudes approximately 0.1 mm to 0.2 mm from the walls 425 n. It is intended that other thicknesses can be configured.

Typically, heat slug pads that have portions that extend beyond the edges of the packages, such as those illustrated in FIGS. 4G-4N, prevent package chips and/or cracks because the protrusions provide for enough spacing between the packages and the singulation device to avoid damage to the packages. These heat slugs are typically larger heat slugs than those in FIGS. 4A-4H. In some embodiments, these larger heat slugs use multiple tie pairs, such as those shown in FIG. 2C.

As discussed above, the heat slug pads can be etched or stamped to obtain a desired form.

Heat Slug Foil

As mentioned above, some embodiments of a heat slug of the present invention are in the form of one or more foil sheets (collectively “heat slug foil”). FIG. 5A illustrates an embodiment of a method 500 of attaching heat slug foil to packages in accordance with the present invention. The method 500 begins at step 505, wherein a plurality of packages is prepared. Typically, the plurality of packages have not yet been singulated from a wafer, a strip or the like. At step 510, heat slug foil is laminated on one side of the packages using thermally conductive material. Typically, the heat slug foil is made from copper, although other metal alloys are contemplated. At step 515, the plurality of packages is singulated such as via saw singulation, laser singulation or punch singulation. The method 500 then ends.

FIG. 5B illustrates an embodiment of a graphical process of producing WLCSPs (wafer level chip scale packages) with attached heat slug pads in accordance with the present invention. At step 1, a wafer of WLCSPs is prepared. At step 2, thermally conductive material is dispensed on the passive side of the wafer. At step 3, heat slug foil is laminated on to the passive side of the wafer using thermally conductive material. At step 4, the thermally conductive material is cured. At step 5, the wafer is diced to produce singulated WLCSPs with attached heat slug pads. As illustrated, a finished unit has a thin layer of heat slug foil coupled to a WLCSP. The width of the heat slug foil is the same as the width of the WLCSP.

FIG. 5C illustrates an embodiment of a graphical process of producing FC-QFN (flip-chip quad flat non-lead) packages with attached heat slug pads in accordance with the present invention. At step 1, a molded strip of FC-QFN packages is prepared. At step 2, thermally conductive material is dispensed on the passive side of the strip. At step 3, heat slug foil is laminated on to the passive side of the strip using thermally conductive material. At step 4, the thermally conductive material is cured. At step 5, the strip is diced to produce singulated FC-QFN packages with attached heat slug pads. As illustrated, a finished unit has a thin layer of heat slug foil coupled to a FC-QFN package. The width of the heat slug foil is the same as the width of the FC-QFN package.

FIG. 5D illustrates an embodiment of a graphical process of producing WB-QFN (wire-bond quad flat non-lead) packages with attached heat slug pads in accordance with the present invention. At step 1, a molded strip of WB-QFN packages is prepared. At step 2, thermally conductive material is dispensed on the active side of the strip. At step 3, heat slug foil is laminated on to the active side of the strip using thermally conductive material. At step 4, the thermally conductive material is cured. At step 5, the strip is diced to produce singulated WB-QFN packages with attached heat slug pads. As illustrated, a finished unit has a thin layer of heat slug foil coupled to a WB-QFN package. The width of the heat slug foil is the same as the width of the WB-QFN package.

It is understood by one skilled in the art that the methods 300, 500 of attaching heat slug pads discussed above can be applied to any package, in addition to the above-discussed WLCSPs, FC-QFN packages and WB-QFN packages. FIGS. 6A-6H illustrate representative packages and do not limit the invention in any way. Each package is coupled to a heat slug pad 605 using thermally conductive material 610. For the sake of clarity, the heat slug pads 605 are shown as blocks. The heat slug pads 605 can be any type of heat slug pads (e.g., pad or foil) and any form, including but not limited to those illustrated in FIGS. 4A-4N and 5B-5D.

FIG. 6A illustrates an embodiment of a FC-QFN package 615 a coupled to a heat slug pad 605 a using thermally conductive material 610 a. The package 615 a includes a chip 620 a, wherein an active side 625 a of the chip is coupled to leads 630 a and a heat spreader 635 a by using solder balls 640 a, in a flip chip style. A passive side 645 a of the chip is coupled to a die pad 650 a using an adhesive 655 a. A heat-conductive and electrically insulated material is a preferred one for the adhesive 655 a. The die pad 650 a is typically a thermally conductive layer made from copper, silicon or any suitable material. The area of the contact interface of the die pad 650 a is smaller than the area of the passive side 645 a. The area of the exposed surface of the die pad 650 a is greater than the area of the contact interface of the die pad 650 a. Preferably, heat accumulated on the chip 620 a is dissipated to the die pad 650 a and the heat spreader 635 a. The molding compound 660 a encapsulates the chip 620 a, the die pad 650 a, the leads 630 a and the heat spreader 635 a to form the package 615 a.

FIG. 6B illustrates another embodiment of a FC-QFN package 615 b coupled to a heat slug pad 605 b using thermally conductive material 610 b. The FC-QFN package 615 b is similarly configured as FC-QFN package 615 a, except that the width of the die pad 650 b is smaller than that of the chip 620 b.

FIG. 6C illustrates yet another embodiment of a FC-QFN package 615 c coupled to a heat slug pad 605 c using thermally conductive material 610 c. The FC-QFN package 615 c is similarly configured as FC-QFN package 615 b, except that the width of the die pad 650 c is the same as or smaller than that of the chip 620 c.

FIG. 6D illustrates yet another embodiment of a FC-QFN package 615 d coupled to a heat slug pad 605 d using thermally conductive material 610 d. The FC-QFN package 615 d is similarly configured as FC-QFN package 615 c, except that the width of the die pad 650 d is the same as the width of the package 615 d.

FIG. 6E illustrates an embodiment of a WB-QFN package 615 e coupled to a heat slug pad 605 e using thermally conductive material 610 e. The package 615 e includes a chip 620 e, wherein a passive side 625 e of the chip 620 e is coupled to a heat spreader 630 e using an adhesive 635 e. An active side 640 e of the chip 620 e has a plurality of bonding pads (not illustrated) for external connections of the chip 620 e. The active side 640 e is coupled to a die pad 645 e using an adhesive 650 e. A heat-conductive and electrically insulated material is a preferred one for the adhesive 635 e, 650 e. The die pad 645 e is typically a thermally conductive layer made from copper, silicon or any suitable material. The area of the contact interface of the die pad 645 e is smaller than the area of the active side 640 e, exposing the bonding pads. The area of the exposed surface of the die pad 645 e is greater than the area of the active side 640 e to maximize the surface area exposed at the top of the package 615 e. Preferably, heat accumulated on the chip 620 e is dissipated to the die pad 645 e and the heat spreader 630 e. The bonding pads are electrically coupled to leads 655 e by bonding wires 660 e. The bonding wires 660 e are made from gold, aluminum, or any suitable material. The molding compound 660 e encapsulates the chip 620 e, the die pad 645 e, the leads 655 e, the heat spreader 630 e and the bonding wires 660 e to form the package 615 e.

FIG. 6F illustrates another embodiment of a WB-QFN package 615 f coupled to a heat slug pad 605 f using thermally conductive material 610 f. The WB-QFN package 615 f is similarly configured as WB-QFN package 615 e, except that the width of the die pad 645 f is smaller than that of the chip 620 f.

FIG. 6G illustrates yet another embodiment of a WB-QFN package 615 g coupled to a heat slug pad 605 g using thermally conductive material 610 g. The WB-QFN package 615 g is similarly configured as WB-QFN package 615 f, except that the width of the die pad 645 g is greater than that of the chip 620 f but smaller than that of the package 615 g.

FIG. 6H illustrates yet another embodiment of a WB-QFN package 615 h coupled to a heat slug pad 605 h using thermally conductive material 610 h. The WB-QFN package 615 h is similarly configured as WB-QFN package 615 g, except that the width of the die pad 645 h is the same as the width of the package 615 h.

As discussed above, the packages illustrated in FIG. 6A-6H are only exemplary and do not limit the invention in any way. Other packages, such as those described in U.S. patent application Ser. No. 11/899,189, filed Sep. 4, 2007, entitled “PACKAGE WITH HEAT TRANSFER,” which is hereby incorporated by reference in its entirety, are also contemplated.

While the invention has been described with reference to numerous specific details, one of ordinary skill in the art will recognize that the invention can be embodied in other specific forms without departing from the spirit of the invention. Thus, one of ordinary skill in the art will understand that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims. 

1. A frame comprising heat slug pads coupled together in a N×M matrix such that singulation of the heat slug pads consists of one or more passes across the frame, wherein the one or more passes are parallel.
 2. The frame of claim 1, wherein each heat slug pad is coupled to another heat slug pad using one or more tie bars.
 3. The frame of claim 2, wherein the one or more tie bars do not have the same thickness as the heat slug pads.
 4. The frame of claim 1, wherein each heat slug pad has one or more tie bars on each non-adjacent side of the heat slug pad.
 5. The frame of claim 1, wherein each heat slug pad includes one or more fiducial alignment marks.
 6. The frame of claim 1, wherein each heat slug pad is etched or stamped to obtain a desired form.
 7. The frame of claim 6, wherein at least a portion of the heat slug pad is half the total thickness of the heat slug pad.
 8. The frame of claim 1, wherein each heat slug pad includes a protrusion along a portion of the heat slug pad.
 9. The frame of claim 8, wherein the protrusion extends between 0.1 mm and 0.2 mm from an edge of a package coupled to the heat slug.
 10. The frame of claim 1, wherein each heat slug pad includes at least two walls to position a package therebetween when the package is coupled to the heat slug.
 11. The frame of claim 1, wherein the thickness of each heat slug pad is between 0.02 mm and 1.0 mm.
 12. The frame of claim 1, wherein the heat slug pads comprise copper.
 13. A method of attaching heat slug pads to packages, the method comprising: gathering a plurality of packages; preparing a heat slug frame including a N×M matrix of heat slug pads coupled together; dispensing thermally conductive material onto surfaces of the heat slug pads; attaching the plurality of packages onto the heat slug pads; and singulating the heat slug pads, wherein the singulating step consists of one or more passes across the N×M matrix, wherein the one or more passes are parallel.
 14. The method of claim 13, wherein the gathering step includes singulating the plurality of packages.
 15. The method of claim 13, wherein the preparing step includes forming the heat slug pads by one of etching and stamping.
 16. The method of claim 15, wherein the forming step results in each heat slug pad including a protrusion along a portion of the heat slug pad.
 17. The method of claim 16, wherein the protrusion extends between 0.1 mm and 0.2 mm from an edge of a package coupled to the heat slug.
 18. The method of claim 15, wherein the forming step results in each heat slug pad including at least two walls to position a package therebetween when the package is coupled to the heat slug.
 19. The method of claim 15, wherein at least a portion of the heat slug pad is half the total thickness of the heat slug pad.
 20. The method of claim 13, wherein the preparing step includes marking the heat slug pads with fiducial alignment marks.
 21. The method of claim 13, wherein the preparing step includes coupling each heat slug pad to another heat slug pad using one or more tie bars.
 22. The method of claim 21, wherein each heat slug pad has one or more tie bars on each non-adjacent side of the heat slug pad.
 23. The method of claim 21, wherein the preparing step further includes etching the one or more tie bars.
 24. The method of claim 21, wherein the preparing step further includes stamping the one or more tie bars.
 25. The method of claim 13, wherein the attaching step includes aligning the plurality of packages to the heat slug pads according to fiducial alignment marks on the heat slug pads.
 26. The method of claim 13, further comprising, after the attaching step, curing the thermally conductive material.
 27. The method of claim 13, wherein the plurality of packages are wafer level chip scale packages.
 28. The method of claim 13, wherein the plurality of packages are flip-chip quad flat non-lead packages.
 29. The frame of claim 13, wherein the plurality of packages are wire-bond quad flat non-lead packages.
 30. A method of attaching heat slug foil to packages, the method comprising: preparing a plurality of packages; laminating the heat slug foil to one side of the plurality of packages using thermally conductive material; and singulating the plurality of packages.
 31. The method of claim 30, further comprising, after the laminating step, curing the thermally conductive material.
 32. The method of claim 30, wherein the plurality of packages are wafer level chip scale packages.
 33. The method of claim 30, wherein the plurality of packages are flip-chip quad flat non-lead packages.
 34. The method of claim 30, wherein the plurality of packages are wire-bond quad flat non-lead packages.
 35. A method of forming a heat slug leadframe, the method comprising: obtaining a heat slug leadframe having at least one heat slug pad and one or more tie bars on each non-adjacent side of the at least one heat slug pad; and preparing at least one heat slug pad such that the at least one heat slug pad has varying thickness across the at least one heat slug pad.
 36. The method of claim 35, wherein the preparing at least one heat slug pad includes forming the at least one heat slug pad.
 37. The method of claim 36, wherein the at least one heat slug pad is formed by one of etching and stamping.
 38. The method of claim 35, wherein the preparing at least one heat slug pad results in the at least one heat slug pad including a protrusion along a portion of the at least one heat slug pad.
 39. The method of claim 35, wherein the preparing at least one heat slug pad results in the at least one heat slug pad including at least two walls configured to position a package therebetween when the package is coupled to the at least one heat slug pad.
 40. The method of claim 35, wherein the preparing at least one heat slug pad includes marking the at least one heat slug pad with one or more fiducial alignment marks.
 41. The method of claim 35, further comprising forming the one or more tie bars.
 42. The method of claim 41, wherein the one or more tie bars are formed by one of etching and stamping. 